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B.

TECH 4
TH
YEAR 8
TH
SEM / ME DEPT./ FIEM / 2013
COMPOSITE MATERIAL FABRICATION
1. Speciality of composite fabrication.
2. Broad classification :
a) Filament Winding (using strands or roving)
i. Cylindrical Winding
ii. Polar Winding
b) Lay up process of unidirectional lamina
c) Material Lay up process
d) Moulding process
i. Vaccume Bag Moulding
ii. Pressure Bag Moulding
iii. Die Moulding
e) Short Fiber Moulding
f) Prepeg Moulding
g) Pultrusion Fabrication

1. Speaciality of Composite Fabrication

a) Does not require much of tooling and machineries.
b) Materials to be handled is limited.
c) Construction methods may change based on application to make the properties tailor made.
d) Power requirement is not much.

2. Broad Classification:

a) FILAMENT WINDING:- Filament winding is a fabrication technique for
manufacturing composite material. The process involves winding filaments under varying amounts of
tension over a male mould or mandrel. The mandrel rotates while a carriage moves horizontally, laying
down fibers in the desired pattern. The most common filaments are carbon or glass fiber and are coated
with synthetic resin as they are wound. Once the mandrel is completely covered to the desired thickness,
the mandrel is placed in an oven to solidify (set) the resin. Once the resin has cured, the mandrel is
removed, leaving the hollow final product. Filament winding is well suited to automation, where the
tension on the filaments can be carefully controlled. Filaments that are applied with high tension results in
a final product with higher rigidity and strength; lower tension results in more flexibility. The orientation of
the filaments can also be carefully controlled so that successive layers are plied or oriented differently from
the previous layer. The angle at which the fiber is laid down will determine the properties of the final
product. Filament winding may be done by using two types of machines: i) Cylindrical Winding m/c and
ii) Polar Winding m/c.
i. Cylindrical Winding Machine: In this winding process one requires a mandrel which for
cylindrical winding m/c having two centers. The mandrel rotates at a low speed. The fiber bobbin is kept in
a vertical rod such that with light tension in fiber strand is released from the bobbin. The fiber is fed to the
mandrel via an eye fitted on a reciprocating block similar to apron box in a lathe machine. In it way to the
apron box eye the fiber is dipped in a bath of liquid resine and then wound on the mandrel. The fibers may
be wrapped at different orientations on the mandrel by changing the gear ratio of head stock suppling power
to the leadscrew which makes the apron box reciprocate. A schematic arrangement is shown below:



ii. Polar Winding Machine: Such machines are used to produce pressure vessels having
cylindrical body with semi-elliptic ends. Such machines are designed in such a way that both cylindrical and
elliptical ends are prepared simultaneously by filament winding.
There is a rotating arm through which the filament in the impregnated condition is fed to a
rotating mandrel made of disposable material like plaster of paris. The mandrel axis is kept at an angle with
respect to the vertical. The rotating arm rotates about a horizontal axis feeding the filament and the mandrel
rotates about its own inclined axis. The result yields a cylinder wound in the polar direction. It is
schematically shown below.


b) Lay up Process:- ( Making of unidirectional lamina in laboratory )
The simple machine that is often used is a cylindrical mandrel mounted on two centers as in a lathe
machine. The filament is wound on this mandrel in a helical path, but the helic angle being very small. It
is usually ignored.
The filament is wound on the mandrel via a resin bath tub in which the filament is impregnated with
resin. After the winding is complete for one layer the layer is cut with a knife parallel to the axis of the
cylindrical mandrel. The layer of filaed ument is then layed up on a steel base or a granite base plate.
Before laying up the impregnated filament layer the base plate is cleaned by spirit and a thin coating of
waxpol is applied on it. Next a top plate of steel or granite is taken and the bottom surface of it is
cleaned and applied with a thin coating of waxpol. Now the top plate is placed on the impregnated
filament layer kept on the base plate. The plates are left in this condition for 24 hours after which they
may be opened. After solidification different specimens are cut as per specification and tested in the
laboratory.


c) Moulding Process:-
In this process a mould is necessary in which the shape of the object is given.
Moulding process may be of three type-
i. Vaccum Bag Moulding:- In this process fiber in the form of woven cloth or mat or
Prepeg , are laid on closed mould. On top of this there is a diaphragm. A prismatic connection connects the
mould to a vaccum pump which evacuates the air from the mould. As a result the diaphragm presses the
impregnated fibers on the mould under pressure of air.


After the fiber and matrix solidify the vaccum is broken and the moulded product is taken out and cured
before use.
ii. Pressure Bag Process:- This process is related to vacuum bag moulding in exactly the same
way as it sounds. A solid female mould is used along with a flexible male mould. The reinforcement is placed inside
the female mould with just enough resin to allow the fabric to stick in place (wet lay up). A measured amount of resin
is then liberally brushed indiscriminately into the mould and the mould is then clamped to a machine that contains the
male flexible mould. The flexible male membrane is then inflated with heated compressed air or possibly steam. The
female mould can also be heated. Excess resin is forced out along with trapped air. This process is extensively used in
the production of composite helmets due to the lower cost of unskilled labor. Cycle times for a helmet bag moulding
machine vary from 20 to 45 minutes, but the finished shells require no further curing if the moulds are heated.


d) Prepeg Moulding :-

A prepreg is a resin-impregnated fiber, fabric, or mat in flat form, which is stored for later
use in hand lay-up or molding operations. Fibers laid at 0 orientation and preimpregnated with resin
are called unidirectional tape. Unidirectional tape provides the ability to tailor the composite
properties in the desired direction. Woven fabric prepregs are used to make highly contoured parts in
which material flexibility is key. It is also used to make sandwich panels using honeycomb as a core
material. Preimpregnated rovings are primarily used in filament winding applications. Epoxy-based
prepregs are very common in industry and come in flat sheet form in a thickness range of 0.127 mm
(0.005 in.) to 0.254 mm (0.01 in.). Prepregs can be broadly classified as thermoset-based prepregs
and thermoplastic- based prepregs/tapes, the difference between the two being the type of resin used.
Reinforcements in a prepreg can be glass, carbon, or aramid,and are used in filament or woven fabric
or mat form in either type of prepreg.



e) Pultrusion Fabrication :-

The pultrusion process represents a continuous transportation of fiber bandles through
a resin matrix bath, following by a dropping of them into a preheated die or a set of dies. After
curing process, where the part is changed from wet saturated reinforcement to a solid par the
pultrusion is saw-cut to desired length.With this process results parts with complex shapes, such as
tubing, channels, I-beams, Z-sections and flat bars. For the composites, the pultrusion process is
equivalent of metals extrusions, with difference that at pultrution the part is pulled from the exit end
of die.

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